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gearbox oil drain plug. Is there a common size?
smart51 - 1/9/09 at 09:20 PM

I tried to replace the diff oil on my Suzuki Cappuccino to find the drain plug is shagged. It seems to be a giant grub screw with a 3/8" square hole (rounded off) to remove. The 2 threads that stick out of the back of the diff have rusted up vice grip teeth marks in one side and is all ripped up on the other.

Being 3/8" drive it must be about 20mm diameter. Are these a common size or do I have to buy a genuine part (at £6.00 plus the same in postage)?

The thing is sized solid to. How do I go about getting it out (with virtually zero access due to the proximity of the rear sub frame and the fins on the diff back plate?

BenB - 1/9/09 at 09:30 PM

You got a 3/8" socket set? Or even better a 3/8" breaker bar. If so jobs a good'un.

Otherwise it's time to buy some silverline sump sockets....

smart51 - 1/9/09 at 09:36 PM

Yep, I have a 3/8 socket set. Trouble is, the hole in the plug is rounded. What's a silverline sump socket?

big-vee-twin - 1/9/09 at 09:57 PM

Silverline is a tool manufacturer, I got a 20mm from a car spares shop cost £2.99 see wilco direct on the web.

Peteff - 1/9/09 at 11:09 PM

You can buy a drain plug tool with multiple ends and one is like a tapered socket fitting. It fits a variety of different plugs like this.

02GF74 - 2/9/09 at 11:16 AM

quote:
Originally posted by smart51
Trouble is, the hole in the plug is rounded.


then a square plug/socket whatever isn't gonna help you.

can you get a 3/8inch bar in the hole and weld it on?, then use adjustable spanner to undo?

or weld in a short bolt.

I reckon it is gonna involve a lot of words not normally spoken in church.

smart51 - 2/9/09 at 11:22 AM

quote:
Originally posted by 02GF74
can you get a 3/8inch bar in the hole and weld it on?, then use adjustable spanner to undo?

or weld in a short bolt.


Now there's an idea. I thought last night that the welder would be needed but I wasn't sure how to go about it.

This morning I had another idea. the filler bolt has come off nicely and I have an oil suction pump (which you need to fill it again). I'll try to get the oil oil out with the pump thing, if there's room to get it in far enough. Otherwise I'll weld a bolt onto it.

BenB - 2/9/09 at 03:12 PM

quote:
Originally posted by smart51
Yep, I have a 3/8 socket set. Trouble is, the hole in the plug is rounded. What's a silverline sump socket?


Oh I see! Thought you meant it was 3/8" but with rounded edges like a socket set....

Get out Mr Mig

Angel Acevedo - 4/9/09 at 11:00 PM

Drill the plug and use a stud remover??

flibble - 5/9/09 at 09:32 AM

Both the fill and drain plugs on my gearbox were the same, had to (as above^^) weld a short bolt into the drain plug and spanner it off, the application of heat also helped loosen things up.
The filler plug was a lost cause though as the gearbox was already in the car (filling a gearbox from the drain plug is reet bugger btw!)

smart51 - 5/9/09 at 01:06 PM

I welded a cut down 10mm bolt to the plug and it came out fairly easily. I guess the heat helped.